Systems, methods, and apparatus useful for busway power distribution

ABSTRACT

A tap-off box includes a mast head apparatus includes a mast head enclosure defining a plurality of stab slots and defining a wire access opening, the plurality of stab slots being vertically aligned along a vertical axis of the mast head enclosure, the wire access opening disposed at a bottom portion of the mast head disclosure. A mast head apparatus includes a thermocouple disposed therein. Alternatively, the thermocouple is disposed in an output box connected to the mast head. The tap-off box is configured for remote control and monitoring.

RELATED APPLICATIONS

This application claims the benefit of priority to U.S. ProvisionalPatent Application No. 62/180,966, titled SYSTEMS, METHODS, ANDAPPARATUS USEFUL FOR BUSWAY POWER DISTRIBUTION, filed Jun. 17, 2015, thedisclosure of which is hereby incorporated by reference herein in itsentirety. This application is a continuation-in-part of co-pending U.S.Non-Provisional patent application Ser. No. 15/185,816, titled SYSTEMS,METHODS, AND APPARATUS USEFUL FOR BUSWAY POWER DISTRIBUTION, filed Jun.17, 2016, the disclosure of which is hereby incorporated by referenceherein in its entirety.

BACKGROUND 1. Field

The disclosure relates to systems, methods, and apparatus for electricalpower distributions systems. In particular, the disclosure relates totake-off devices, such as power heads, for use with busbar busway powerdelivery systems.

2. Introduction

Electrical power distribution systems are useful for providing flexiblepower delivery options in a broad range of operating environments,including offices, warehouses, garages, and factories to provide anelectrical power source for lighting and other electrical devices andequipment. In particular, busway distribution systems must be developedto accommodate structural features and clearance requirements imposed bythe workspaces and equipment, raceways, piping, and encumbrances presentin the environments for which they are most useful. For example, busbarbusway power distribution systems are widely used for powering computersystems in large data centers, and they continue to gain popularity fortheir growing omnipresence, ease of installation, and ease of customconfiguration and re-configuration.

Busway systems include one or more tracks or sections that each containselectrically isolated conductive bars called busbars that extend alongan inner length of a track housing of a busway frame and enclosurecommonly known as “open channel busway.” The housing may be constructedof extruded aluminum, for example, and provide a ground that meetsapplicable standards, and may have a withstand rating of at least 22 kA,for example. Preferably, busbar busway power distribution systems arecapable of operating continuously without mechanical or electricaldamage, degradation, or derating of operating capability under thefollowing example conditions: 1) ambient temperature of electroniccomponents in range from 32 degrees to 104 degrees Fahrenheit (0 degreesto 40 degrees Celsius); 2) relative humidity of 0 percent to 90 percent,non-condensing; and 3) altitude in a range from sea level to 4000 feet(1220 m). Preferably busways should meet UL857, be configured to supplyrated full-load current; should be rated to 600 VAC and 600 VDC; andshould be fully rated to interrupt symmetrical short-circuit currentwith a minimum three-cycle short-circuit rating of up to 42 Ka RMSsymmetrical. The housing defines an opening or channel that enablesaccess to the busbar contained within the housing. Open channel buswaytracks or sections may be joined together to form power distributioncircuits. Busway housing section lengths may be custom defined for aparticular application.

Busway systems have been developed for side and overhead installation oftrack sections to a wall or ceiling, respectively, to accommodate avariety or installation options and application limitations imposed byequipment or installation environments. A top of a busway track orsection may include or define a slot or channel running along a lengthof the busway to provide attachment points for installation of thebusway in an operating environment. An opposing side or bottom of thebusway track may include or define a conductor access opening, which maybe a continuous or substantially continuous opening extending along alength of the track or section. The conductor access opening isconfigured to accept one or more plug-in units and facilitate anelectrical connection between a conductive portion of the one or moretake-off devices or plug-in units and the conductive busbars disposed inthe busway housing.

Busway sections may be connected to one another to form a customconfiguration as desired, and may be efficiently re-configured ifnecessary. Systems may include an end cap installed at an end of alength of busway section(s). A joint kit or bus connector is used toform electrical and mechanical connections between busway sections andpower feeds by way of compression or bolted means. A power feed thatprovides connection from incoming cables to the busway system. The powerfeed includes an NEMA enclosure having access panels configured forcabling and cable access. The power feed includes an internal connectionto a section of busway conductors within a busway. The power feed maybeavailable as an End Feed or a Center or Top Feed box for accommodatingexisting wire and conduit feeder runs for termination to the End Feedbox.

Busway systems may include conductive busbars formed of pure copper, orcopper and aluminum, and may be sized to handle 100% of the buswayrating under continuous operation up to the maximum ambient temperature.The conductors should be isolated from the housing. An isolated groundmay be implemented in the busway track housing the busbars. The busbarsor conductors may include a neutral of 1.732 times the conductor rating,for example. Busbars may be formed of high strength 98% conductivitycopper, for example, and should be capable of carrying rated currentcontinuously without exceeding a temperature increase of 55 degreesCelsius based on a 40 degree Celsius ambient temperature.

A take-off device may be inserted into the open channel busway conductoraccess channel to form an electrical connection with busbars containedtherein to enable the take-off device to draw power from the busway. Thepower may be used to load a range of devices ranging from lighting tolarger electronic equipment. Larger ampere ratings of larger take-offdevices benefit from enhanced contact area and pressure of a connectionbetween busbars and conductive portions of the take-off devices. Somebusway systems are configured to include a busbar assembly having anouter portion that is insulative, and an inner, concentrically nestedconductive portion. An outer portion of the busbar assembly providesstructural support, while the inner conductive portion is flexible andhas spring-like resiliency. The outer portion, which may be formed ofaluminum or an alloy, for example, may have a generally U-shape orV-shape, and may include a slot opening through which conductiveportions or stabs or a take-off device pass before engaging in pressurecontact with the inner conductive portion. In particular, the innerconductive portion may include substantially parallel conductors thattogether define a conductor channel for accepting and securing byspring-contact the stab within the busbar assembly, and thereby,clamping the stab within the housing of the busway track or section,applying pressure and achieving maximum surface contact between the staband the conductors. In some systems, the conductive portions may includea substantially planar surface that may not be configured to contactmultiple faces of a stab.

Plug-in units or take-off devices or units also interchangeably referredto herein throughout as power heads, mast heads, power delivery outlets,or output boxes, may use a circuit breaker or a fuse for branch circuitprotection. Plug-in units are configured to include conductive stabs, asdiscussed above, for insertion into a slot or channel defined by a trackof a busway bar system wherein the inserted stab contacts a conductor orconductive busbars disposed within the track. Plug-in units may havelocking clips, bolt-on tabs, or other fastening devices or systems forsecuring the units to the busway. Plug-in units may include drop cordswith cord grips and appropriately configured receptacles. The units maybe selected, configured, and arranged for balancing a load based on aquantity of plug-in units and unit types. Plug-in units preferably mayhave at least 35 amperes of distribution capacity for 250, 400, and 800ampere systems. Thermal magnetic trip-type circuit breakers for branchcircuit protection may be used. The units maybe configured for removalfrom a busway system without requiring that power delivered to thebusway be suspended or shut down, and they may include integratedshutters.

SUMMARY

A need has been recognized for improved power distribution power heads,mast heads, plug-in units, or electrical power outlet units. Mast headsin accordance with embodiments improve safety, enhance performance andefficiency, and enable improved form factor, ease of installation intobusway systems, enhanced stability, and enhanced monitoring and controlwhen installed in the same.

In an embodiment, a mast head apparatus includes a mast head enclosurehaving an interior and defining a wire access opening and a plurality ofstab slots; and a thermocouple disposed in an interior of the mast head,or in the interior of an output box attached to the mast head, or acombination thereof.

In another embodiment, a mast head apparatus includes a mast headenclosure defining a plurality of stab slots and defining a wire accessopening, the plurality of stab slots being vertically aligned along avertical axis of the mast head enclosure, the wire access openingdisposed at a bottom portion of the mast head disclosure.

In another embodiment, a conductive stab for a mast head apparatus mayinclude a first chamfered end configured for insertion into a conductorof a busway bar track, the first chamfered end including a firstchamfered surface and a second chamfered surface, the first and thesecond chamfered surfaces extending from respective principal surfacesthat extend parallel to a longitudinal axis of the stab; and a secondend for connecting to a wire.

In an embodiment, a tap-off box apparatus includes a mast head, the masthead comprising a mast head enclosure having an interior and defining awire access opening and a plurality of stab slots, the mast headenclosure shaped and configured for operable insertion into a buswaypower distribution system; an output box connected to the mast head, theoutput box define an interior; and a thermocouple disposed in theinterior of the output box and configured to detect a temperaturetherein.

In an embodiment, a tap-off box apparatus, includes a mast head; anoutput box; and a control module, the control module configured tocontrol an output power from the tap-off box apparatus. In anotherembodiment, the tap-off box apparatus includes a communications module,the communications module configured to connect the tap-off boxapparatus to a communications network. In another embodiment, thecommunications network is a network selected from the group comprisingbluetooth communication, WLAN, WPA, WEP, Wi-Fi, or wireless broadband,or any combination thereof. In another embodiment, the communicationsnetwork is a wired network, a wireless network, or a combinationthereof.

In an embodiment, the tap-off box apparatus includes a transceiver, thecommunications module to configured to receive and transmits datacarrying signals.

In an embodiment, the control module is configured for remote controlthrough the communications network facilitating remote control ormonitoring of the tap-off box apparatus. In an embodiment, a toggleswitch is disposed on the output box and configured to control an on oroff state of the output power from the tap-off box.

In an embodiment, a take-off device system, includes a tap-off boxcomprising a mast head for electrical connection to a power distributionsystem, the tap-off box comprising a controller and a communicationsmodule together configured for remote monitoring and control of thetap-off box; and an access point geographically remotely located withrespect to the tap-off box and configured to access a communicationsnetwork to which the tap off box is connected for remote control andmonitoring of the tap-off box.

In an embodiment, a take-off device system includes a first tap-off boxcomprising a mast head for electrical connection to a power distributionsystem, the tap-off box comprising a controller and a communicationsmodule together configured for remote monitoring and control of thetap-off box, the first tap-off box connected to a communicationsnetwork; a second tap-off box comprising a second communications moduleand configured for remote monitoring and control of the second tap-offbox, the second tap-off box connected to the communications network; andaccess point geographically remotely located with respect to the tap-offbox and configured to access the communications network for remotecontrol and monitoring of the tap-off box.

Additional features and technical effects of the present disclosure willbecome readily apparent to those skilled in the art from the followingdetailed description wherein embodiments of the present disclosure aredescribed simply by way of illustration of the best mode contemplated tocarry out the present disclosure. As will be realized, the presentdisclosure is capable of other and different embodiments, and itsseveral details are capable of modifications in various obviousrespects, all without departing from the present disclosure.Accordingly, the drawings and description are to be regarded asillustrative in nature, and not as restrictive.

BRIEF DESCRIPTION OF DRAWINGS

The embodiments of the present disclosure are shown by way of example,and not by way of limitation, in the figures of the accompanying drawingand in which like reference numerals refer to similar elements and inwhich:

FIG. 1 shows a mast head of a take-off device in accordance with anexemplary embodiment;

FIG. 2 shows a top perspective view of the mast head of FIG. 1 inaccordance with an exemplary embodiment;

FIG. 3A shows a first side view of the mast head of FIG. 1 in accordancewith an exemplary embodiment;

FIG. 3B shows a second side view of the mast head of FIG. 1 inaccordance with an exemplary embodiment;

FIG. 4 shows a conducting stab and connected wire in accordance anexemplary embodiment;

FIG. 5 shows a table of exemplary stab and wire configurations;

FIG. 6 shows stab characteristics corresponding with values shows in thetable of FIG. 5;

FIG. 7A shows a cross-sectional side view of a mast head having seated,spring-fitted stabs in accordance with an exemplary embodiment;

FIG. 7B shows a cross-sectional end view of a mast head having seated,spring-fitted stabs in accordance with an exemplary embodiment;

FIG. 7C shows a cross-sectional end view of a mast head having seated,spring-fitted stabs in accordance with an exemplary embodiment;

FIG. 8 shows an enclosure of a take-off device for us with a mast headin accordance with an exemplary embodiment;

FIG. 9 shows a cross-sectional side view of a take-off device engagedwith a busway system having a thermocouple extending from the mast headin accordance with an exemplary embodiment;

FIG. 10A shows a cross-sectional side view of a take-off device engagedwith a busway system having a thermocouple and forced air flow system inaccordance with an exemplary embodiment;

FIG. 10B shows a cross-sectional side view of a take-off device engagedwith a busway system having a thermocouple disposed in an enclosure ofthe take-off device in accordance with an exemplary embodiment;

FIG. 11 shows a cross-sectional side view of a take-off device engagedwith a busway system having a thermocouple and passive airflow system inaccordance with an exemplary embodiment;

FIG. 12A shows a cross-sectional side view of a take-off device engagedwith a busway system having a thermocouple and forced airflow system inaccordance with another exemplary embodiment;

FIG. 12B shows a side view of the take-off device of FIG. 12A;

FIG. 13 shows a bottom cross-sectional perspective view of a take-offdevice engaged with a busway system having a thermocouple and passiveairflow system in accordance with an exemplary embodiment

FIG. 14A shows a cross-sectional side view of a take-off device engagedwith a busway system having a thermocouple and forced airflow system inaccordance with another exemplary embodiment;

FIG. 14B shows a cross-sectional side view of a take-off device engagedwith a busway system having a thermocouple and forced airflow system inaccordance with another exemplary embodiment;

FIG. 15 shows a tap-off box in accordance with another exemplaryembodiment;

FIG. 16A shows a an embodiment of a remotely controllable tap-off box;

FIG. 16B shows a an embodiment of a remotely controllable networkedtap-off box system.

DESCRIPTION

In the following description, for the purposes of explanation, numerousspecific details are set forth in order to provide a thoroughunderstanding of exemplary embodiments. It should be apparent, however,that exemplary embodiments may be practiced without these specificdetails or with an equivalent arrangement. In other instances,well-known structures and devices are shown in block diagram form inorder to avoid unnecessarily obscuring exemplary embodiments. Inaddition, unless otherwise indicated, all numbers expressing quantities,ratios, and numerical properties of ingredients, reaction conditions,and so forth used in the specification and claims are to be understoodas being modified in all instances by the term “about”.

A mast head and take-off device power head having enhanced safetyfeatures may be configured to minimize a risk of improper or unsafeinstallation or removal of the power head or plug-in unit in or from thebusway bar power delivery system. For example, some busway systems maybe configured to include or accommodate a busway plug-in inhibitorsystem or component for rotational take-device or output box units. Aninhibitor system may include a structural feature that inhibitsover-rotation or improper rotation, or may include a system for alertingor warning a user about the potential, likelihood, or occurrence ofimproper rotation of a power head or paddle during removal of the powerhead from the busway bar that is under load, which can result inproperty damage and personal injury. An inhibitor system may beconfigured for implementing in existing busway bar systems withoutrequiring modification of an existing installation and thereby enablingefficient retro-fitting and updating of busway power delivery systemsthat have already been deployed.

There is a need for monitoring and control of output boxes and othercomponents such as end feed units and the like to enhance safety andefficient operability of busway power distribution systems. There is aneed, for example, for remote monitoring of operating conditions such astemperature and on or off state of a tap-off box or unit including anoutput box and a mast head that connects the output box to a busway waybar. There is also a need for remote control of a tap-off box. There isstill further a need for a system wherein tap-off boxes are configuredfor networked communication using wired or wireless networks, or acombination of both. These needs and others are met by embodimentsdisclosed herein.

The need for remote monitoring and control or tap-off units, and easier,secure, and safe installation may be addressed and systems enhancedthrough take-off device configurations in accordance with embodimentsdisclosed herein. For example, a power head or mast head 100 inaccordance with an exemplary embodiment is shown in FIG. 1. Inparticular, FIG. 1 shows a head enclosure 101 having conducting stabsextending from an interior of the head enclosure 101 to an exteriorthereof. Stabs 105 extending from a first side of the head enclosure 101protrude from a plurality of stab slots 107 defined by the headenclosure 101. Stabs 109 may extend from a second side of the headenclosure 101. Wires connected to the stabs 105 and 109 extend from aninterior of the head enclosure through an opening 111 defined thereby.FIG. 1 shows wires 115 extending through the defined opening 111. FIG. 1shows that a thermocouple may be fitted in the head enclosure and extendthrough the defined opening in accordance with some embodiments.

A need for stable, enhanced, improved, and maximized electricalconnectivity between stabs of a power head or output box and aconducting member or bar assembly of a busway track system has beenrecognized. The stabs 105 and 109 extend for insertion into a buswayconductor track slot or opening to make an electrical connection betweenwires contained within the power head and the conductor of the buswaytrack. The stabs slots defined by the head enclosure 101 may bevertically aligned on at least one side of the head enclosure 101 forenhanced internal wire configuration and improved installationefficiency, safety, connectivity, and stability.

FIG. 2A shows a top perspective view of a first side of the headenclosure 101 of FIG. 1. The mast head includes a ground slot 217through which no stab extends. Additionally, FIG. 2 shows air flowopenings 221 defined by the mast head for passive cooling or toaccommodate forced air through-flow. One of more air flow openings 221may be defined in a mast head exterior and optimally arranged forminimizing mast head interior operating temperatures.

FIG. 2B shows a top perspective of a first side of the head enclosure101 of FIG. 1. FIG. 2B shows air flow openings 223 arranged a top of themast head for passive cooling and to accomodate air flow, force orotherwise. The air flow openings 223 are configured and arranged toalign with a channel of a busway into which the mast head is inserted.

FIG. 3A shows a side view of a first side of the head enclosure 101 ofthe mast head 100 of FIG. 1. The stabs 105 are not vertically aligned.Further, the ground slot 217 is not vertically aligned with the stabs105. In some embodiments, the mast head 100 may not include a groundslot 217. FIG. 3B shows a side view of a second side of the headenclosure 101 of the mast head 100 of FIG. 1. The stabs 109 arevertically aligned. This configuration accommodates enhancedinstallation convenience and safety and stability for contact betweenthe conductive stab surface and busway conductors into which the stabsare inserted.

FIG. 4 shows a top perspective view of a stab assembly 400. The stabassembly 400 includes a conductive stab 405 connected to a wire 415.Various gauges of wire may be used including sizes being orcorresponding to, or about or substantially American Wire Gauge sizesincluding #4 AWG and #6 AWG, for example. Preferred wire gauges may be agauge in a range of from #4 AWG to #12 AWG, for examples. There is aneed for a power head that may accommodate larger wire gauges including#6 and #4 sizes. Related are power head assemblies include internalconfigurations, for example, that limit a size of wire that may becontained within the base and cap subs-assembly. Vertically aligned stabopenings, and in some cases, removal of the isolated ground opening,provides internal room for configurations that can accommodate largerwires sizes. A stab width may be appropriately increased forcorrespondingly larger wire gauges. For example, it has been found thata stab width of 0.375 to 0.378 may be advantageous for use with a #4 AWGwire. A width of a stab for use with #6 AWG or #8 AWG may becorrespondingly smaller, for example.

There is a need for output boxes having an optimal structuralconfiguration that enables enhanced power delivery and maximizedelectrical contact between a stab of the output box and a conductingsurface of a busway track. There is also a need for an output box withmonitoring functionality, and in particular, thermal monitoringfunctionality. Thermal monitoring using a thermocouple as shown in FIG.1 may enable targeted temperature monitoring at an installed output box,which can enhance applications in large data centers that often operateat high temperatures well over room temperatures, commonly known as “hotaisles.”

The stab is a conductive component that may be formed of any suitableconductive material, and that is connected to a wire to facilitate anelectrical connection between busbars contained within a busway trackand wire contained within a take-off device or output box. A stab 405 asshown in FIG. 4 may have a rounded or chamfered end configured forenhanced and efficient insertion into a busway bar slot, track, oropening. This configuration enhances and maximizes surface area contactbetween a stab and a conductor of a busway bar system to enhanceelectrical connectivity, which is enhanced in pressure-fit busbarassembly systems wherein the stab contacts the conductors underpressure.

The stab 405 shown in FIG. 4 is advantageously configured and shaped foroptimal surface area contact with a conductor bar of a busway barsystem. For example, an end of the stab may be configured to include twochamfered edges that extend from principal surface of the stab along alongitudinal axis of the stab. The chamfer angles of the two chamfersurfaces shown in the figures above is 20 degrees. It has been fond thata stab having chamfered edges, particularly with chamfer angles of 20degrees, exhibits enhanced electrical connectivity and easesinstallation into busway bar tracks or openings.

It has been found that a modified stab width may be advantageous forusing wire gauges of particular sizes. For example, large stab widthsmay be appropriate for larger gauge wires. The dimensions andconfigurations shown FIG. 5 are illustrative and non-limiting.Additionally, the drawings of the stab in FIG. 6, to which the table ofFIG. 5 refers are not necessarily to scale.

FIG. 5 shows stab assembly dimensions and specifications by way ofexample with reference to wire gauges of various sizes including #4 AWG,#6 AWG, #8 AWG, and #10 AWG. The specifications include values ofdistances in units of inches. A stab having a width of between 0.375inches and 0.378 inches may be advantageous for use with a #4 AWG wire.

A need has been recognized for providing larger diameter wire accessopenings in mast head or output boxes useful for busway busbar systems.For example, for a main lug 3 phase 208/120 VAC output box that isconfigured to work with three hot busbars, one neutral busbar, and oneisolated ground bar, 85 amperes may be provided by way of a one inchconduit defined in the busway mast head. Larger wire access diametersmay be implemented to accommodate larger number or gauge wires. Forexample, a 1.25 inch or 1.5 inch wire access opening or conduit may beused to accommodate larger gauge wires, or a larger number of wires.While these diameters are provided by way of example, the wire accessopening or conduit may be made to include diameters of other sizes toaccommodate particular wires sizes and numbers as appropriate

FIG. 7A shows a stab assembly seated in a busway system including stabs705 having springs 731. The springs may be constructed and arranged ofany suitable now known or later developed materials and configuration.The springs 731 may be configured to enable the stab 705 to retract adistance within the head enclosure during insertion of the mast headinto a busway system, and to extend under spring action through the stabslot until fully extended and inserted into a busway conductor assembly.The spring force may be sufficient to permit retraction duringinsertion, and in some embodiments, may be sufficient to enhanceinsertion and position of the stab in the conductor assembly. FIG. 7Bshows a cross-sectional end view of the stabs 705 and springs 731 in anextended position.

FIG. 7C shows a stab assembly 705 having a rear contact portion 737configured for contacting an internal member such as a divider in masthead enclosure. An exemplary divider 738 is shown. The divider 738includes spring structures 739 that decompress when the rear contactportion 737 is urged toward the divider 738 and against the springstructures 739.

A need has been recognized for enhanced take-off device configurationsfor accommodating larger wire sizes. For example, a mast head as shownin FIG. 1 may be configured to define or include stab slots that arealigned for optimal busway mounting, having an interior wherein one ofwires are arranged for optimal space conservation. It has beenrecognized that the isolated ground feature is rarely used for manyapplications today, and additional space for advantageous internalconfiguration of the mast head may be defined by eliminating theisolated ground from mast head and cap and base sub-assemblyconfigurations in accordance with apparatus of embodiments.

A need has been recognized for improved take-off device configurationsfor use with a mast head as shown in FIG. 1, for example. FIG. 8 showsan enclosure for use with a mast head of FIG. 1 for receiving the wires115 of the FIG. 1, and for providing other functions. FIG. 8 shows theenclosure 800 having support structures 835. An enclosure in accordancewith an embodiment may have at least one such support structure 835 forsecuring a take-off device to a busway system. The enclosure 800 mayinclude slots 837 defined by the enclosure 800. The slots 837 mayfacilitate communication between an interior of the enclosure 800 and aninterior of a busway channel when the take-off device to which theenclosure 800 is attached is installed in a busway system, as shown inFIG. 9.

A need has been recognized for enhanced power monitoring for take-offdevices. Busway bar power delivery systems may optionally include powerfeed monitoring systems and functionality. A power feed may be providedwith power measurement capability and a remote monitoring interface formonitoring at least one of the following: input voltage (L/L and L/N);current per phase (Min/Max); voltage per phase (Min/Max); neutralcurrent; power factor; frequency; power (active, reactive, apparent);demand (kWH); voltage and current THD %; and current peak demand,preferably with an accuracy of better than 0.5%.

A need as been recognized for enhanced monitoring using a plug-in unitmonitoring system for top feed and center feed boxes. An output boxmonitoring system may be configured with power measurements capabilityand remote monitoring interface for monitoring at least one of thefollowing: input voltage (L/L and L/N); current per phase (Min/Max);voltage per phase (Min/Max); power factor; frequency; power (active,reactive, apparent); demand (kWH); current peak demand, preferably withan accuracy of better than 1%. Plug-in monitoring systems must beserviceable without requiring that the plug-in be removed or powereddown, and must support 1, 2, and 3 pole circuits with varyingconfigurations up to 8 circuits per plug-in unit. Plug-in monitoringsystems may optionally be further configured for power qualitymonitoring including: voltage and current harmonics up to the 63rdharmonic, current and voltage harmonic magnitudes and angles (perphase), phase rotation, sequence components, voltage THD, current THD,input voltage (L/L and L/N); current per phase (Min/Max); voltage perphase (Min/Max); power factor; frequency; power (active, reactive,apparent); demand (kWH); current peak demand, temperature, humidityusing a Dallas 1-wire, for example, and preferably with an accuracy ofbetter than 0.5%.

Systems in accordance with embodiments may be advantageously configuredfor real-time power monitoring. In an embodiment, control monitoringcomponents may be configured to facilitate fast sampling at a ration of,preferably, twice per second. Monitoring may be configured to includecoverage of a single take-off box, or multiple take-off boxes.

A mast head 101 connected to an enclosure 800 and including athermocouple for thermal monitoring in accordance with an embodiment isshown in FIG. 10A. The mast head is configured to accept and secure athermocouple that is connected to a wire. The wire extends along withone or more other wires that may be connected to one or more stabs,respectively, for delivering power. Accordingly, a take-off device maybe advantageously configured for thermal monitoring. Similarly, existingassemblies of pre-deployed output boxes may be retrofitted to include amast head that is configured to receive and secure a thermocouple forthermal monitoring. The thermocouple may be connected to any now knownor later developed monitor or monitoring system such as a digitalmonitor suitable for collecting and transmitting real-time temperature,humidity and dew point data to protect, for example, large data centerequipment and personnel from heat and moisture. A digital sensor may beconfigured for remote temperature sensing and power monitoring. Suchsensors and monitoring systems are now commercially available fromGEIST, for example.

In an alternative embodiment, the take-off device may be implementedwith a thermocouple or any now known or later developed sensor fordetection of a temperature within the output box, or the enclosureconnected to the mast head. FIG. 10B shows the thermocouple disposed inthe output box. In an alternative embodiment, the thermocouple may beconfigured in a top opening of the mast head for detecting a temperatureof an interior of the busway into which the mast head is inserted (notshown).

FIG. 10A shows cross-sectional side view of a take-off device having amast head 101 connected to an enclosure 800 in accordance with anembodiment. The enclosure 800 shown in 10A optionally includes a fan1041 positioned at a bottom of the enclosure 800, beneath the mast head101, and above an airflow duct 1043 that communicates with an interiorof the enclosure 800 by way of the fan 1041.

A need has been recognized for a cooling system that is based on a setpoint triggered by obtaining a measurement from a monitoring system thatis configured to monitor thermal activity at the mast head in a buswaybar power delivery system or at an output box connected to a busway. Abusway cooling and monitoring system may include a cold air deliverysystem that is configured for delivering air from a cold aisle sectionof a data center rack, for example, or other cold air source, to anoutput box. A temperature-activated fan may be set at 100 degreesFahrenheit and draw the cold air into the output box to maintain anambient temperature at the output box of under 104 degrees Fahrenheit.The fan may be mounted in the output box, or outside of the output box.The fan may be any suitable now known or later developed fan or otherdevice useful for producing air current and drawing cool air, or inalternative configurations, forcing cool air. A controller may becoupled to the fan and to a monitoring system for controlling the fan inresponse to temperature readings or determinations made by themonitoring system. Multiple fans and monitoring systems, sensors,controllers, or associated devices may be used. A need has also beenrecognized for monitoring and control of humidity. Suitable now known orlater developed sensors may be implemented for communicating humidityinformation, which may be used to inform temperature or air flowcontrol. Accordingly, issues associated with, for example, condensationinduced by temperature control measures including air cooling may beaddressed.

FIG. 11 shows a cross-section view of a take-off device having a masthead 101 connected to an enclosure 800. In the embodiment of FIG. 8, theenclosure 800 does not include a fan, or air flow duct communicatingthrough a fan.

FIG. 12 A shows a cross-sectional side view of a take-off device havinga mast head 101 connected to an enclosure 1251 in accordance with anembodiment. The enclosure 1251 includes a fan positioned at a bottom ofthe enclosure 800, beneath the mast head 101, and above an airflow duct1043 that communicates with an interior of the enclosure 800 by way ofthe fan 1041. The enclosure 1251 includes a single tab disposed distalto mast head 101 at a top of the enclosure 1251. The tab 1255 may beused to secure the take-off device to a busway system.

As shown in FIG. 12B, as outside of the enclosure 1251 of FIG. 12A mayinclude a digital readout 1257 and a toggle switch 1259 in accordancewith an embodiment. Other now known or later developed output, display,or user input devices may be implemented for use with take-off devicesin accordance with embodiments. The digital readout 1259 of FIG. 12Bprovides temperature monitoring and control, humidity monitoring andcontrol, or a combination of the same. In association, fans may beconfigured for activation based on a determined humidity level.

In one cooling system, a cool air delivery system may be configured atthe busway for maintaining an ambient temperature of below 104 degreesFahrenheit. One or more fans may be configured for drawing cold air fromthe cold aisle and supplying the air to the busbar assembly in thebusway. The busway may include strips, shutters, or the like forcovering and substantially sealing openings of the busway whereby airmay be ducted into the busway from the cold aisle, or ducted from datacenter CRAC units disposed at various points along a busway. The air maybe ducted using a modified plug-in output box with fan and an open slot.When the modified plug-in output box is installed in a busway, the openslot enables an interior of the output box to communicate with thebusway thereby enabling air to flow from the output box into the busway.

FIG. 13 shows a bottom cross-sectional perspective view of an enclosure800 with a mast head opening 111 and wires 115 extending therein. Theenclosure 800 is connected to a busway system and the air flow openings837 facilitate air flow between an interior of the enclosure 800 and aninterior of the busway channel.

FIG. 14A shows a cross-sectional side view of a take-off device engagedwith a busway system having a thermocouple and forced airflow system inaccordance with another exemplary embodiment. FIG. 14A shows a mast head101 installed in the busway system and attached to an enclosure 800. Theenclosure 800 is connected to air source by an air flow duct 1461 at aside of the enclosure. The air source is a air conditioning unit 1463. Afan 1465 disposed at the air conditioning unit 1463 forces air,including cool air, through the air flow duct 1461 and into theenclosure 800 for circulation in the enclosure 800 and mast head 101.

FIG. 14B shows a cross-sectional side view of a take-off device engagedwith a busway system having a thermocouple and forced airflow system inaccordance with another exemplary embodiment. FIG. 14A shows a mast head101 installed in the busway system and attached to an enclosure 800. Theenclosure 800 is connected to air source by a air flow duct 1461 at abottom of the enclosure 800. The air source is an air conditioning unit1463. A fan 1465 disposed at an interior bottom of the enclosure 800 andforces air, including cool air, through the air flow duct 1461 and intothe enclosure 800 for circulation in the enclosure 800 and mast head101.

FIG. 15 shows a cross-sectional side view of a take-off device engagedwith a busway system in accordance with another exemplary embodiment.FIG. 14A shows a mast head 101 installed in the busway system andattached to an enclosure 800. The enclosure 800 includes a circuitbreaker panel or load center 1571 for providing switching function andprotection.

In an embodiment, a tap-off box or output box or take-off deviceincludes a controller for controlling the power of the tap-off box. Inanother embodiment, the tap-off box includes a controller configured tooperate and control the tap-off box and its functions, includingmonitoring functions. For example, the tap-off box may includecontactors or similar suitable device and circuitry configured tocontrolling an output load of the tap-off box.

FIG. 16A shows a an embodiment of a tap-off box for remote control,monitoring, or a 10 combination thereof. In particular, tap-off boxincludes a mast head 101 installed in the busway system and attached toan enclosure 800. The enclosure 800 includes a controller 1681 andcircuitry configured to control output power from the tap-off box. Thecontroller 1681 may be configured to locally controlled to turn on oroff the output power of the tap-off box. The controller 1681 isconfigured to remotely control the output power of the tap-off box by acommunications module 1684 and associated components constructed andarranged for operable remote wired or wireless communications.Alternatively, or additionally, the enclosure 800 includes a monitoringsystem as disclosed herein that is configured, for example, formonitoring a temperature of an interior of the mast head 101, in theinterior of the enclosure 800, or a combination thereof (not shown).

For example, in the embodiment shown in FIG. 16A, the communicationsmodule 1684 may include a receiver, transmitter, or transceiverconfigured for communications for short range to long rangecommunications using now known or later developed communicationsprotocols and associated devices and equipment. For example, thecommunications module and associated components may be selected andconfigured for bluetooth communication, or WLAN, WPA, WEP, Wi-Fi, andwireless broadband. For example, In an embodiment, systems may beconfigured for remote control and monitoring using, among other things,5G wireless communications.

As shown in FIG. 16B, the tap-off box shown in FIG. 16A may beimplemented in a tap-off box system network 1686. The system network1686 may include client tap-off boxes 1788 in networked communicationand connected to an access point 1691. The system network may includecell phone networks, wireless local area networks, wireless sensornetworks, and satellite communications networks. The client device mayitself have a transceiver, and may be configured to form an ad hoc ormesh network with other client device tap-off boxes of the network 1686.Alternatively, or additionally, the network 1686 may include separaterepeaters, such as simple transceiver devices, or devices havingadditional functionality, including routing functionality. Accordingly,remote temperature or other device and condition monitoring and devicecontrol is facilitated by the tap-off box system network 1686.

Embodiments are shown by way of example, and not by way of limitation inthe figures and drawings.

While the invention has been described in connection with a number ofembodiments and implementations, the invention is not so limited butcovers various obvious modifications and equivalent arrangements, whichfall within the purview of the appended claims. Although features of theinvention are expressed in certain combinations among the claims, it iscontemplated that these features can be arranged in any combination andorder.

1. A power distribution apparatus useful for busway power distributionsystems, comprising: an enclosure configured for containing componentsfor electrical connection to the a busway power distribution system; anda thermocouple disposed in an interior of the enclosure.
 2. A mast headapparatus, comprising: a mast head enclosure defining a plurality ofstab slots and defining a wire access opening, the plurality of stabslots and the wire access opening sized and configured to accommodate aplurality of wires each having a wire size of or substantiallycorresponding to American Wire Gauge (AWG) #4 size wire or and a sizeabove AWG #4.
 3. (canceled)
 4. (canceled)
 5. (canceled)
 6. (canceled) 7.(canceled)
 8. (canceled)
 9. The apparatus of claim 1, comprising: aremote monitoring system connected to the thermocouple for receivingthermal data obtained by the thermocouple.
 10. The apparatus of claim 9,the enclosure further comprising: an output box, comprising: a cold airdelivery system for delivering cold air from a cold aisle section of adata center rack or other cold air source to the output box to maintainan ambient box temperature of under 104 degrees Fahrenheit; atemperature-activated or humidity-activated fan configured to draw airinto the output box, the fan disposed adjacent to, on, or in the outputbox, wherein the fan is configured to draw the cold air into the outputbox; and a conduit space defined by the wire access opening connectingthe output box to a mast head, wherein the conduit is configured toallow cold air to pass through the conduit into the mast head andthrough one or more air flow apertures defined in a surface of the masthead, wherein the apertures are round in shape or comprise one or moreslits.
 11. The apparatus of claim 2, comprising: a output box having aninterior connected to the interior of the mast head by the wire accessopening, the output box defining top openings for communicating with abusway channel.
 12. (canceled)
 13. (canceled)
 14. (canceled) 15.(canceled)
 16. (canceled)
 17. The apparatus of claim 2, the wire sizebeing or substantially corresponding to AWG #6 wire size.
 18. Theapparatus of claim 1, comprising: a controller configured to monitor atemperature in the enclosure based on measurements obtained by thethermocouple.
 19. The apparatus of claim 2, comprising the wire accessopening having a diameter of greater than one inch for providing 85amperes and configured to connect to three hot busbars and one neutralbusbar, and an isolated ground busbar of a busway bar delivery system.20. The apparatus of claim 1, the enclosure further comprising: anoutput box comprising a load center, the load center connected to aplurality ow wires extending from the mast head, through the wire accessopening, into the output box.
 21. (canceled)
 22. The apparatus of claim1, comprising: a control module, the control module configured tocontrol an output power from the apparatus.
 23. The tap-off boxapparatus of claim 23, comprising: a communications module, thecommunications module configured to connect the apparatus to acommunications network.
 24. The apparatus of claim 23, thecommunications network further comprising a network selected from thegroup comprising bluetooth communication, WLAN, WPA, WEP, Wi-Fi, orwireless broadband, or any combination thereof.
 25. The apparatus ofclaim 23, the communications network further comprising a wired network,a wireless network, or a combination thereof.
 26. The apparatus of claim24, comprising: a transceiver, the communications module to configuredto receive and transmits data carrying signals.
 27. The apparatus of 23,the controller configured for remote control through the communicationsnetwork facilitating remote control or monitoring of the.
 28. Theapparatus of claim 27, comprising: a toggle switch disposed on theoutput box and configured to control an on or off state of the outputpower from the tap-off box.
 29. The apparatus of claim 23 furthercomprising the controller and the communications module togetherconfigured for remote monitoring and control of the tap-off box; and anaccess point geographically remotely located with respect to the tap-offbox and configured to access a communications network to which the tapoff box is connected for remote control and monitoring of the tap-offbox.
 30. apparatus of claim 23, the apparatus being a first tap-off box,the first tap-box comprising a mast head for electrical connection to apower distribution system, the first tap-off box comprising a controlmodule and a communications module together configured for remotemonitoring and control of the first tap-off box, the first tap-off boxconnected to a communications network to which a second tap-off box isconnected, wherein the a second tap-off box comprises a secondcommunications module and configured for remote monitoring and controlof the second tap-off box, the second tap-off box connected to thecommunications network; and access point geographically remotely locatedwith respect to the first tap-off box and configured to access thecommunications network for remote control and monitoring of the firsttap-off box.
 31. The apparatus of claim 30, the control moduleconfigured to facilitate fast sampling at a ratio of, preferably, twiceper second.
 32. The apparatus of claim 1, the enclosure furthercomprising: a output box.
 33. The apparatus of claim 1, the enclosurefurther comprising: an end feed box.
 34. The apparatus of claim 1, theenclosure configured for insertion and non-rotational engagement foroperable connection to the power distribution system.
 35. The apparatusof claim 1, the enclosure configured for insertion and rotationalengagement for operable connection to the power distribution system. 36.The apparatus of claim 2, the wire access opening further comprising adiameter of one inch.
 37. The apparatus of claim 2, the wire accessopening further comprising a diameter of greater than one inch.